Why 63% of Child-Resistant Blister Failures Trace to These 3 Design Flaws
After a major recall of arthritis medication last quarter, CPSC investigators traced 82% of failures to a single design oversight in push-through blister packs. Regulatory data reveals that nearly two-thirds of child-resistant (CR) failures stem from three preventable flaws. Here’s how to avoid becoming a statistic.
The Failure:
44% of rejected CR blisters fail due to incorrect push-through force (per ASTM D3475)
Too weak (<8 lbf): Children access contents in 5 seconds
Too strong (>15 lbf): Seniors can’t access medication
The Fix:
▶️ Use differential pressure technology: Center requires 12 lbf, corners need 5 lbf
▶️ Specify glass-filled PETG trays (0.5% shrinkage vs. PVC’s 3%) for force consistency
▶️ Validate with real-world testing: 50 seniors + 50 children across age groups
PVC blister foils to soften, reducing push-force by 30%
Cavity distortion creating accidental "easy-open" corners
Adhesive delamination on blister cards
The Fix:
▶️ Switch to humidity-resistant PETG materials (only 0.2% moisture absorption)
▶️ Implement laser-scored tear lines as secondary barrier
▶️ Add desiccant slots in multi-dose blister packs
The Failure:
27% of failures involve audible "confirmation clicks" that don’t indicate full barrier breach
Children learn to stop after hearing the sound
Adults assume medication is accessible when it’s not